Partitioned soap and process of forming the same



Feb. 16, 1943. w, BODMAN ETAL' 2,310,931

PARTITIONED SOAP AND PROCESS OF FORMING THE SAME Filed July 27, 1940 e mfm H mm v? 0 m M 4 3, 5

Patented Feb. 16, 1943 PARTITIONED SOAP AND PROCESS OF FORMING THE SAME John W. Bodman, Winchester, and Fred Forrest Pease, Squantum,

Mara, assignors to Lever Brothers Company, Cambridge, Mass, a corporation of Maine Application July 21, 1940, Serial Na-348,008

15 Claims.

This invention relates to the forming of a weakened zone or cleavage plane in a detergent mass, such as soap, to facilitate the subdivision of the mass into a plurality of smaller units. More particularly, the invention is concerned with a bar of soap having a weakened zone or cleavage plane permitting the bar to be broken at such zone with relative ease and without the formation of unsightly rough surfaces at the break.

It is known that framed soaps for household use, for example, are customarily molded and sold in large cakes and are often cut or broken into more convenient sizes when used. In order to facilitate this sub-dividing of the bar, it has been a common practice to score or notch the bar during molding to indicate where the bar should be broken and to make easier the subdividing. This practice has proven unsatisfactory for several reasons. The resulting fracture usually faiied to follow the score marks and as a result cakes of irregular size and shape were formed. Also the broken portions of the bar have unattractive rough fractured surfaces which collect dirt and which are harsh to the touch. In many instances where soaps have become drier and harder with age, it has been notedthat irrespective .of whether the bar has been notched or scored it cannot be broken in two by a user, at leastvnot without considerable effort.

We have found that a detergent mass, such as soap, may be so treated along a zone or plane passing through it that a weakened zone or cleavage plane is formed permitting a clean even break and one which is relatively easy to obtain. This is accomplished by movement of said mass relative to a treating surface. The reason for the effectiveness of the treating surface is not fully understood, but apparently it acts to modify the crystalline, fibrous or other texture of the mass in such a manner as to cause a zone of weakness or cleavage. The treated surfaces must be caused to rebond, fuse, reunite or intermingle to a sufficient extent to avoid complete separation. The amount or degree of reuniting may be controlled and would depend up-- on the mass treated and the type of partitioned product desired. Y

Our invention may be practiced with respect to a soap mass in such a manner as to form a bar or cake of soap which may be broken easilyv along a predetermined plane forming at the break relatively smooth surfaces of attractive appearance. This partioning plane or weakened of the bar and its function is not aflected by aging or use.

Figure 1 is a perspective view of a preferred form of apparatus for carrying out the invention: Figure 2 is a diagrammatic indication of the flow of the soap mass through the apparatus: and

or cake made susceptible for partitioning in ac;- cordance with our invention.

As an illustration of our invention, we may use a soap mass in a plastic or molten condition. The soap mass may be in an aerated condition and have a marshmallow-like consistency and appearance. The soap should preferably be in such a heated condition that if separated. and brought together again without substantial heat loss, it will rebond into an integral, uniform, continuous mass with no residual surfaces apparent. The strength of'the rebonded zone is controllable as will be subsequently described. The preferred treating temperatures with regard to a soap mass may be between 160 and 225 F. although higher temperatures may be used as well as lower. Temperatures as low as 145 F. have been found to be satisfactory andtemperatures as low as 120 F. may be used providing conditions are such that a satisfactory reuniting zone in no way detracts from the appearance of the separated streams 'is obtained. The temperatures of the surfaces to be reunited are more critical than the temperature of the entire mass with regard to substances of the type of soap having the characteristic of rewelding. The composition of the mass is an important factor aifectingthe temperature of treatment.

The mass to be treated may be charged vdirectly into a conduit I0 illustrated in Figure 1. This conduit may be of any cross-section 'dependent usually upon the nature of the final product desired. ,In the conduit in, we have positioned a vane II which temporarily divides the stream after which it reforms or coalesces into a single stream in the manner shown by the ar-,

rows in Figure 2.

The vane l I is illustrated. as a streamlined type designed to minimize turbulence in the flowing material. In this connection we have also illustrated the vane H as having a smooth, but extended, surface in order to obtain a desired frictional contact of the stream without such turbulence as would distort the film or surface in contact with the vane. After passing the vane I I the mass under treatment may be further formed, cooled or otherwise treated. The stream however, should preferably Figure 3 is a perspective view of a soap bar be fur-ther treated with a minimum of disturbance to the zone which has been in contact with the vane II. After solidification, the illustrative soap bar is found to have a plane or zone indicated by reference character I4 of Figure 3, having a weakened structure relative to the general mass of' the soap bar, coinciding with the plane along which the soap mass was divided by the vane I I. This weakened zone in the bar, as indicated in Figure 3, permits a partitioning of the bar with relative ease and with a. clean. smooth break.

It should also be noted that the vane II should be positioned in the conduit In in such a way as to be effective to form the partitioning plane in the desired position in the final product. This positioning of the vane would depend, of course, upon the manner in which the unit products are cut or separated from the continuous mass as formed, for example, in the conduit l9.

The vane I I need not extend through the entire mass under treatment in the manner shown in Figure l, but may extend in from the outer surfaces of the conduit I0, toward but not through the center of the stream. Similarly, the

partitioning vane may be supported in the middle of the stream-so that the weakening planes do not extend out to the edges of the bar. Also the vane may be adjusted and shaped suitably for different thicknesses of the stream and different positions within the stream. These variations in the position and form of vane are dependent primarily upon the extent or type of partitioning or weakening plane which is desired in the final product and to permit suitable adjustment for the characteristics of the stream, such as, for example, viscosity or plasticity, rate of flow, temperature, composition and other factors. If desired, more than one vane may be used. For example, a series of vanes may be positioned one tloning plane for the soap bar. When the cake of soap so treated is fractured along such a plane, the fractured surfaces are relatively smooth and uniform and may show evidence of a lamellar structure with the individual lamellae positioned parallel to the plane of fracture. The difference in crystalline texture in the planar zone from the texture of the soap outside the zone is readily after the other in the stream. We have noted able smoothness to the fractured surface when the cake is broken along the partitioning plane so formed. Also two or more vanes may be positioned across the stream so as to form in the mass under treatment two or more weakening or partitioning planes.

We believe that an explanation of the formation of the weakened zone in a mass of soap may be found in the modification of the crystalline texture of the mass. A soap mass, in a preferred embodiment of the invention, may'have a crystalline texture with the crystals positioned at random throughout the mass. By forcing the mass of soap past an obstmctlon such as the streamlined vane positioned in he moving stream, friction is developed between the soap mass and thesurface of the vane. This friction apparently brings about a rearrangement or orientation of the solid or so-called liquid soap crystals in proximity to the vane surface dependent upon the temperature of the soap mass. When the streams meet after passing the vane, they can and do immediately rebond or reunite, in view of the molten or fusible condition of the soap at these surfaces, into a single mass of soap.

apparent upon examination, and we believe that this diflerence in crystalline texture explains the partitioning plane in the soap bar. Other than this we do not wish to be limited in our invention to any theory or explanation.

We have found, however, that it is desirable to use a vane of such form or section as to avoid or minimize turbulence in the stream that is in the plastic or mobile mass passing the vane. We believe that in accordance with the explanation given above that any turbulence tends to reduce the time and effectiveness of the frictional contact of a given surface and thus reduces the tendency towards orientation of the crystals, fibers or other particles making up the mass under treatment. Also turbulency tends to remove from the zone of orientation particles which may have become oriented, and the degree of orientation is diminished. A further reason for the desirability of such a form of vane or other structure or operation as will minimize turbulency is that after the passage of the mass beyond the vane any turbulency in the ,mass tends to distort the position of any zone of orientation which may have been formed. Such distortion causes an uneven break in the partitioning zone.

We have also found it desirable in the treatment of soap, for example, to use a polished or burnished surface on the separating or orienting vane to minimize the tearing, gouging or other distortion of the surface of the mass in contact with the vane. Such distortion of the surface film may result from excessive frictional drag. In this connection a smooth chromium plated vane has been found to be satisfactory. The area of the vane should be sufficient to obtain the desired frictional contact with the soap mass to bring about crystalline orientation.

After being subjected to orientation only sufficient pressure need be applied to the separated streams of the'mass to bring the surfaces capable of being reunited into contact. For example, the soap charged to the conduit I0 of Figure 1 should be sufficient to fill the space after passing the vane II and thus act to direct into contact again the separated streams. In view' of the molten or fusible condition of the mass coalesence under conditions results. It is possible, therefore, in addition to the formation of an oriented cleavage plane to control and vary the type of weakened zone to be produced in 9. treated mass. This may be done by a control of the temperature of the divided streams, particularly at the moment they are again brought together. If the divided surfaces having the oriented rearranged crystalline texture are slightly cooled, the tendency for the surfaces upon reuniting to coalesce and fuse is reduced. Thus the bond formed between the reunited streams is further weakened for in addition to the weakening effect of orientation, there rangement of the crystalline texture may be formed ;in opposed surfaces in a milled soap; These opposed surfaces then may be made to fuse or coalesce without loss of the oriented structure. The presence of such an oriented plane ina milled soap gives a weakened zone facilitating partitioning.

It is possible with masses having the characteristics of soap, for example, to provide a partitioning plane within the mass by the formation of a slip or cleavage plane without the use of a treating vane. By way of illustration two separate streams of soap having surfaces capable of fusing may be brought into contact in such a way that one flows or slips over the surface of the other and preferably without material turbulence. The slippage at the surface tends to form a cleavage plane between the surfaces upon rebonding which subsequently may be utilized as a partitioning plane. This operation may, if desired, be combined with the use of a treating surface or vane as described above.

Temperature control of the surfaces under treatment may be accomplished by using a vane having a chamber l2 fitted with suitable conduits l5 and control valves l5 permitting the application of cooling or heating media.

A further weakening of the cleavage zone may be accomplished by cutting into the edges of the solidified soap cake at the cleavage zone. This may be done with any suitable cutting means, such as thin knives. After cutting to any desirable distance, but insufficient to sever the bar, the cake may be pressed, molded or stamped in such a way as to render invisible the narrow supplementary slits.

While we have described our invention primarily in connection with soap, it is applicable to other substances having a structure capable of orientation and capable of fusion, rebonding or otherwise reuniting after the formation of the oriented zone or zones. The detergent compositiorr for example, may include animal or vegetable fatty acid soap or the higher fatty nonsoap detergents of the Igepon and Gardinol types,

as well as others having suitable characteristics. Various compositions or blends of fatty acids in the soap type of detergents may be used, and

- potassium as well as the sodium salts, dependent upon the characteristics desired in the final product and the factors involved in costs and manufacturing conditions. aerated forms may be utilized.

We claim:

l. A method of treating soap to facilitate the partitioning of a mass of such soap which comprises dividing a heated mass of soap by causing said soap to flow relative to a dividing element to alter the arrangement of the soap crystals along a predetermined planar zone in the soap mass to decrease the natural cohesion of the soap Aerated as well as noncrystals in the said zone, and causing the divided mass of soap to rebond after passing said dividing element.

2. A method of treating a mass of a detergent selected from the group consisting of soap and higher fatty non-soap detergents to facilitate subsequent partitioning of said mass, comprising providing a continuous flow of said mass in a coalescent condition, obstructing the flow along a predetermined plane in the said mass to cause division of at least a portion of the flow into separate streams, reuniting the said streams, and permitting said mass to solidify without material disruption of said plane.

3. A method of treating a mass of a detergent selected from the group consisting of soap and higher fatty non-soap detergents to facilitate partitioning which comprises dividing a heated mass of said detergent and creating a streamlined fiow in the opposed surfaces of said mass to minimize turbulence therein, and rebonding said surfaces to form a planar zone of structural weakness in the otherwise uniform mass.

4. A method of treating a soap mass of substantially uniform composition to facilitate partitioning which comprises providing a mass of said soap at a temperature at which it would coalesce and rebond, dividing said mass and altering the crystalline texture in the opposed surfaces of the divided portions, and permitting said surfaces to contact each other, whereupon they rebond and coalesce to form a planar zone of altered crystalline texture which is weaker than the remainder of the soap mass.

5. A bar of soap formed of a soap mass of substantially uniform composition throughout and having a zone the crystalline texture of which is different from the crystalline texture in the remainder of the bar and less cohesive so as to facilitate partitioning of the soap bar in said zone while retaining the otherwise uniformity of the soap mass.

6. A bar of a detergent selected from the group consisting of soaps and higher fatty non-soap detergents, having a planar zone therein, the crystalline texture and composition of the detergent in at least the portions of said bar adjacent said zone being substantially the same and of substantial uniformity, the crystalline texture .of the detergent in said zone being substantially uniform but different fromthe crystalline texture in said adjacent portions, whereby said bar may be readily partitioned in a plane in said zone.

7. A bar of soap having a planar zon'e therein, the crystalline texture and composition of the soap in at least the portions of said bar con-- tiguous to said zone being substantially the same and of substantial uniformity, the soap in said zone having an arranged crystalline texture different from the crystalline texture in said contiguous portions, whereby said bar may be readily partitioned in a plane in said zone.

8. A bar of ,soap having a relatively narrow planar zone of soap and contiguous portions of soap comprising the remainder of the bar, the soap in the contiguous portions of said bar having a crystalline texture with the crystals positioned at random, the soap in said zone having an arranged crystalline texture which is less cohesive when subject to a force to partition the bar, whereby said bar may be readily partitioned in a plane in said zone.

9. A bar of soap having a relatively narrow planar zone of soap and contiguous portions of soap comprising the remainder of the bar, the soap in the contiguous portions of said bar having a crystalline texture characteristic of milled soap, the soap in said zone having an arranged crystalline texture different from the crystalline texture in said contiguous portions and less cohesive when subject to a force to partition the bar, whereby said bar may be readily partitioned in a plane in said zone.

10. A bar of a detergent selected from the group consisting of soaps and higher fatty nonsoap detergents having a planar zone therein, the crystalline texture and composition of the detergent in at least the portions of said bar adjacent said zone being substantially the same and of substantial uniformity, the crystalline texture of the detergent in said zone being substantially uniform but different from the crystalline texture in said adjacent portions, and cuts extending into said bar from at least two of the faces of said bar and in substantial alignment with said zone, whereby said bar may be readily partitioned in a plane in said zone.

11. A bar of soap having a relatively narrow planar zone of soap therein and contiguous portions of soap comprising the remainder of the bar, the soap in the contiguous portions of the bar being substantially the same and having a crystalline texture that is of substantial uniformity, the soap in said zone having an arranged crystalline texture, different from the crystalline texture in said contiguous portions and less cohesive when subjected to a. force to partition the bar, and cuts on at least two of the faces of said bar extending into said bar in substantial alignment with said zone, whereby said bar may be readily partitioned in a plane in said zone.

12. A method of treating a mass of detergent selected from the group consisting of soap and higher fatty non-soap detergents to facilitate partitioning; which comprises forming the mass, while heated to a coalescent condition, into at least two parts; causing relative movement between at least one surface of each part and solid means in contact with said surfaces and uniting said surfaces whereby they rebond and coalesce to form a mass that is uniform and homogeneous other than a rearranged crystalline texture in the detergent in a planar zone comprising the united surfaces.

13. A method of treating a mass of soap to facilitate partitioning which comprises providing a mass of said soap heated to a coalescent condition, dividing and simultaneously causing relative movement between the opposed surfaces of said mass and ,the dividing member while said surfaces are in contact with said dividing member, and rebonding said surfacesto form a rearranged crystalline texture in the soap in a planar zone comprising the rebonded and coalesced surfaces.

14. A method of treating a mass-of soap to facilitate partitioning which comprises dividing a mass of said soap heated to a coalescent condition and causing the'opposed surfaces to flow past an immovable surface while in contact therewith, and rebondingsaid surfaces to form a rearranged crystalline texture in the soap in a planar zone comprising the rebonded and coalesced surfaces.

15. A method of treating a mass of detergent selected from the group consisting of soap and higher fatty non-soap detergents to facilitate partitioning, which comprises'dividing a mass of said detergent in a coalescent condition causing relative movement between the opposed surfaces of said mass and the dividing member, rebonding said surfaces to form a rearranged crystalline texture in the detergent in a planar-zone com prising the rebonded surfaces, hardening the mass to form a bar, and placing cuts in the bar in substantial alignment with the planar zone to further weaken but not sever the mass in said zone.

' JOHN W. BODMAN.

FRED FORREST PEASE.

4 CERTIFICATE OF commoner. Patent No. 2,510,951. February 1 191 JOHN w. BODMAN, ET AL.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correctionas follows: Page 2, -sec-- ond column, line 55, after the word "under" insert --such--; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 50th day of March, A. D. 1915.

Henry Van Arsdale,

(Sea1) Acting Commissioner of Patents. 

